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Section 1 (Engine 3.7L Ti-VCT): Assembly: Engine

WARNING: This page is about a different variant/trim than selected.

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s) 

GFD91562Courtesy of FORD MOTOR COMPANY
 2, 200# Floor Crane, Fold Away 300-OTC1819E
GFD91409Courtesy of FORD MOTOR COMPANY
 Alignment Pins 307-399
GFD91713Courtesy of FORD MOTOR COMPANY
 Compressor, Piston Ring 303-D032 (D81L-6002-C)
GFD91010Courtesy of FORD MOTOR COMPANY
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GFD91565Courtesy of FORD MOTOR COMPANY
 Eye, Engine Lift 303-1245
GFD91535Courtesy of FORD MOTOR COMPANY
 Handle 205-153 (T80T-4000-W)
GFD91494Courtesy of FORD MOTOR COMPANY
 Hold Down, Secondary Chain 303-1530
GFD91388Courtesy of FORD MOTOR COMPANY
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
GFD91393Courtesy of FORD MOTOR COMPANY
 Installer, Front Cover Oil Seal 303-335
GFD91536Courtesy of FORD MOTOR COMPANY
 Installer, Differential Bearing Cone 205-142 (T80T-4000-J)
GFD91389Courtesy of FORD MOTOR COMPANY
 Installer, Front Crankshaft Seal 303-1251
GFD91537Courtesy of FORD MOTOR COMPANY
 Installer, VCT Spark Plug Tube Seal 303-1247/2
GFD91567Courtesy of FORD MOTOR COMPANY
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GFD91474Courtesy of FORD MOTOR COMPANY
 Tool, Camshaft Holding 303-1248

Material 

Item Specification
Motorcraft ® High Temperature Nickel Anti-Seize Lubricant XL-2 -
Motorcraft ® High Performance Engine RTV Silicone TA-357 WSE-M4G323-A6
Motorcraft ® Metal Surface Prep Wipes ZC-31-B -
Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil (US); Motorcraft ® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada) WSS-M2C945-A
Motorcraft ® Silicone Gasket Remover ZC-30-A -
Motorcraft ® Orange Concentrated Antifreeze/Coolant VC-3-B (US); CVC-3-B2 (Canada) WSS-M97B44-D
Motorcraft ® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
Motorcraft ® Thread Sealant with PTFETA-24-B WSK-M2G350-A2

Engine Upper 

GFD91714Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 12C508 Engine control wiring harness
2 9424 Upper intake manifold
3 9F797 Fuel rail
4 9J444 Upper intake manifold support bracket
5 9J447 Lower intake manifold
6 8A586 Thermostat housing
7 9N271 Coolant tube
8 12A699 Knock Sensor(KS)

Engine Front 

GFD91715Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 W701512 Crankshaft pulley bolt
2 N806165 Crankshaft pulley washer
3 6316 Crankshaft pulley
4 6700 Crankshaft front seal
5 6B209 Accessory drive belt tensioner
6 6019 Engine front cover

Engine Upper - LH Cylinder Head 

GFD91716Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 6083 LH cylinder head gasket
2 6050 LH cylinder head
3 12405 Spark plug (3 required)
4 6500 Valve tappet (12 required)
5 6A269 LH exhaust camshaft
6 6A267 LH intake camshaft
7 6C525 Exhaust camshaft Variable Camshaft Timing (VCT) assembly
8 6C524 Intake camshaft VCT assembly
9 6C256 LH secondary timing chain
10 6B297 Exhaust camshaft VCT oil control solenoid
11 6B297 Intake camshaft VCT oil control solenoid
12 6B280 Camshaft mega cap
13 6K297 LH secondary tensioner shoe
14 6A258 LH camshaft cap (6 required)
15 6K602 Valve train oil feed tube
16 6C270 LH secondary timing chain tensioner
17 6K273 LH valve cover
18 6750 Oil level indicator

Engine Upper - RH Cylinder Head 

GFD91717Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 6051 RH cylinder head gasket
2 14B485 CHT sensor jumper harness
3 6G004 Cylinder Head Temperature (CHT) sensor
4 17A084 Engine lift eye
5 6049 RH cylinder head
6 12405 Spark plug (3 required)
7 6500 Valve tappet (12 required)
8 6A266 RH intake camshaft
9 6A268 RH exhaust camshaft
10 6A258 RH camshaft cap (8 required)
11 6K602 Valve train oil feed tube
12 6C525 Exhaust camshaft Variable Camshaft Timing (VCT) assembly
13 6C524 Intake camshaft VCT assembly
14 6C256 RH secondary timing chain
15 6B280 Camshaft mega cap
16 6K297 RH secondary tensioner shoe
17 6B297 Exhaust camshaft VCT oil control solenoid
18 6B297 Intake camshaft VCT oil control solenoid
19 6C270 RH secondary timing chain tensioner
20 6K271 RH valve cover

Timing Drive Components 

GFD231093Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 6268 Timing chain
2 6306 Crankshaft timing sprocket
3 6L266 Primary timing chain tensioner
4 6K255 Primary timing chain tensioner arm
5 6B274 LH lower primary timing chain guide
6 6K297 RH primary timing chain guide
7 6K297 LH upper primary timing chain guide
8 8501 Coolant pump

Lower Engine Block (View 1) 

GFD91719Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 6675 Oil pan
2 6622 Oil pump screen and pickup tube
3 6625 Oil pump screen and pickup tube O-ring seal
4 6621 Oil pump
5 6010 Cylinder block
6 6D327 Crankshaft rear seal retainer
7 12A227 Crankshaft sensor ring
8 6375 Flexplate
9 9278 Engine Oil Pressure (EOP) switch
10 6881 Oil filter adapter
11 6714 Engine oil filter
12 6881 Oil filter adapter with oil cooler
13 6A642 Oil cooler

Lower Engine Block (View 2) 

GFD91720Courtesy of FORD MOTOR COMPANY
Item Part Number Description
1 - Piston compression upper ring (part of 6148) (6 required)
2 - Piston compression lower ring (part of 6148) (6 required)
3 - Piston oil control upper segment ring (part of 6148) (6 required)
4 - Piston oil control spacer (part of 6148) (6 required)
5 - Piston oil control lower segment ring (part of 6148) (6 required)
6 6140 Piston pin retainer (12 required)
7 6135 Piston pin (6 required)
8 6110 Piston (6 required)
9 6200 Connecting rod (6 required)
10 6211 Connecting rod upper bearing (6 required)
11 6211 Connecting rod lower bearing (6 required)
12 - Connecting rod cap (part of 6200) (6 required)
13 6010 Cylinder block
14 6K868 Piston oil cool valve (6 required)
15 6333 Cylinder block crankshaft main bearing (4 required)
16 6A341 Crankshaft upper thrust washer (2 required)
17 6303 Crankshaft
18 6A338 Lower crankshaft main bearings (4 required)
19 6K302 Crankshaft lower thrust washer
20 6325 Lower crankshaft main bearing caps (4 required)
21 6C364 Main bearing cap support brace
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods and pistons). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System General Information .
NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.

All vehicles 

  1. Using a hexagonal screwdriver, install the 6 piston oil cool valves.

    • Tighten to 4 Nm (35 lb-in).

    GFD91695Courtesy of FORD MOTOR COMPANY
  2. NOTE: This step is for selecting the correct main bearings.
    NOTE: The #1 main bearing is at the front of the engine block.

    Select the crankshaft main bearings for each crankshaft journal.

    • Record the code that is on the cylinder block face.
    • Record the code that is on the crankshaft flange.
    • The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.

    GFD91721Courtesy of FORD MOTOR COMPANY
  3. NOTE: This chart is continued in the next step.
    NOTE: This chart is for selecting main bearings 1 and 4 only.

    Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4.

    • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
    • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing.
    • As an example, if the engine block code letter is "M" and the crankshaft code letter is "M", the correct bearing grade for this main bearing is a "2" for the upper bearing and a "2" for the lower bearing.
    • Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.

    GFD91722Courtesy of FORD MOTOR COMPANY
  4. NOTE: This chart is for selecting main bearings 1 and 4 only.
    GFD91723Courtesy of FORD MOTOR COMPANY
  5. NOTE: This chart is continued in the next step.
    NOTE: This chart is for selecting main bearings 2 and 3 only.

    Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3.

    • Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code.
    • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 2 crankshaft main bearing.
    • As an example, if the engine block code letter is "N" and the crankshaft code letter is "H", the correct bearing grade for this main bearing is "2".
    • Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.

    GFD91724Courtesy of FORD MOTOR COMPANY
  6. NOTE: This chart is for selecting main bearings 2 and 3 only.
    GFD91725Courtesy of FORD MOTOR COMPANY
  7. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Using the original connecting rod cap bolts, install the connecting rod caps and bolts.

    • Tighten the bolts in 3 stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.

    GFD91726Courtesy of FORD MOTOR COMPANY
  8. Measure the connecting rod large end bore in 2 directions.

    • Remove the bolts and the rod cap.

      • Discard the connecting rod cap bolts.

    GFD91727Courtesy of FORD MOTOR COMPANY
  9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
    GFD91728Courtesy of FORD MOTOR COMPANY
  10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    GFD91729Courtesy of FORD MOTOR COMPANY
  11. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

    Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 upper crankshaft main bearings in the cylinder block.

    GFD91730Courtesy of FORD MOTOR COMPANY
  12. NOTE: Do not install the upper thrust bearings until the crankshaft is installed.
    NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.

    Install the crankshaft onto the upper main bearings.

    GFD91692Courtesy of FORD MOTOR COMPANY
  13. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

    Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.

    GFD91731Courtesy of FORD MOTOR COMPANY
  14. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

    Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.

    GFD91732Courtesy of FORD MOTOR COMPANY
  15. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in caps.
    GFD91733Courtesy of FORD MOTOR COMPANY
  16. NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps.
    NOTE: Early build engine shown, late build engine similar.

    Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.

    GFD91734Courtesy of FORD MOTOR COMPANY
  17. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
    NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

    Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.

    GFD91690Courtesy of FORD MOTOR COMPANY
  18. NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps.
    NOTE: Early build engine shown, late build engine similar.

    Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.

    GFD91735Courtesy of FORD MOTOR COMPANY
  19. NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps.
    NOTE: Early build engine shown, late build engine similar.
    NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.

    Tighten the main bearing bolts in the sequence shown in 2 stages.

    • Early build engines - Stage 1: Tighten fasteners 1 through 8 to 33 Nm (24 lb-ft).
    • Early build engines - Stage 2: Tighten fasteners 1 through 8 an additional 135 degrees.
    • Late build engines - Stage 1: Tighten fasteners 1 through 8 to 27 Nm (20 lb-ft).
    • Late build engines - Stage 2: Tighten fasteners 1 through 8 an additional 180 degrees.

    Fig 1: Main Bearing Bolt Tightening Sequence
    GFD91736Courtesy of FORD MOTOR CO.
  20. Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in 2 stages.

    • Stage 1: Tighten fasteners 1 through 8 to 45 Nm (33 lb-ft).
    • Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.

    Fig 2: Main Bearing Cap Side Bolt Tightening Sequence
    GFD91737Courtesy of FORD MOTOR CO.
  21. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.

    1. Position the crankshaft to the rear of the cylinder block.
    2. Zero the Dial Indicator Gauge.
    3. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.

    GFD91738Courtesy of FORD MOTOR COMPANY
  22. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Prepare the connecting rod and cap.

    • Insert the new bolts in the rod cap.
    • Insert the upper and lower rod bearings into the rod and cap.

    GFD91739Courtesy of FORD MOTOR COMPANY
  23. Before installing the pistons into the cylinder block, verify proper ring gap location.

    1. Center line of the piston parallel to the wrist pin bore
    2. Upper compression ring gap location
    3. Upper oil control segment ring gap location
    4. Lower oil control segment ring gap location
    5. Expander ring and lower compression ring gap location

    GFD91712Courtesy of FORD MOTOR COMPANY
  24. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
    NOTE: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown.
    NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
    NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to Piston .
    NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.
    NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.

    Using the Piston Ring Compressor, install the piston and connecting rod assemblies.

    • Seat the connecting rod on the crankshaft journal.

    GFD91740Courtesy of FORD MOTOR COMPANY
  25. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation.

    Install the 6 connecting rod cap and the 12 bolts.

    • Tighten the bolts in 3 stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
    • Repeat the previous 3 steps and this step until all 6 piston, connecting rod and connecting rod cap assemblies are installed.

    GFD91686Courtesy of FORD MOTOR COMPANY
  26. NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps.
    NOTE: Early build engine shown, late build engine similar.

    Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in 2 steps.

    • Early build engines - Stage 1: Tighten to 24 Nm (18 lb-ft).
    • Early build engines - Stage 2: Tighten an additional 180 degrees.
    • Late build engines - Stage 1: Tighten to 27 Nm (20 lb-ft).
    • Late build engines - Stage 2: Tighten an additional 225 degrees.

    Fig 3: Main Bearing Cap Support Brace Bolt Tightening Sequence
    GFD91741Courtesy of FORD MOTOR CO.
  27. NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.
    NOTE: The stamped steel crankshaft rear seal retainer plate comes with the crankshaft rear seal.

    Apply a 3 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.

    GFD91742Courtesy of FORD MOTOR COMPANY
  28. NOTE: Lubricate the crankshaft rear seal with clean engine oil.

    Install the crankshaft rear seal retainer and the 8 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    Fig 4: Crankshaft Rear Seal Retainer Bolt Tightening Sequence
    GFD91408Courtesy of FORD MOTOR CO.
  29. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
  30. Install the oil pump and the 3 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD91488Courtesy of FORD MOTOR COMPANY
  31. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD91684Courtesy of FORD MOTOR COMPANY
  32. NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan.

    Install the A/C compressor and the 2 bolts.

    • Tighten to 25 Nm (18 lb-ft).

    GFD91743Courtesy of FORD MOTOR COMPANY
  33. NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    Apply a 3 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the oil pan.

    GFD91744Courtesy of FORD MOTOR COMPANY
  34. NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

    Apply a 5.5 mm (0.21 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.

    GFD91745Courtesy of FORD MOTOR COMPANY
  35. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.

    Install the oil pan and bolts 10, 11, 13 and 14.

    • Tighten the bolts in the sequence shown to 3 Nm (27 lb-in).
    • Loosen the bolts 180 degrees.

    GFD91746Courtesy of FORD MOTOR COMPANY
  36. Align the oil pan to the cylinder block and the A/C compressor.

    • Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.

    GFD91747Courtesy of FORD MOTOR COMPANY
  37. Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in).
    GFD91748Courtesy of FORD MOTOR COMPANY
  38. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown.

    • Tighten the large bolts (1-14) to 24 Nm (18 lb-ft).
    • Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).

    GFD91749Courtesy of FORD MOTOR COMPANY
  39. Install the A/C compressor mounting stud and nut.

    • Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).

    GFD91750Courtesy of FORD MOTOR COMPANY
  40. Install the coolant pump and the 8 bolts. Tighten in the sequence shown in 2 stages:

    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

    Fig 5: Coolant Pump Bolt Tightening Sequence
    GFD91751Courtesy of FORD MOTOR CO.
  41. Install the Knock Sensor (KS) and the 2 bolts.

    • Tighten to 20 Nm (177 lb-in).

    GFD91682Courtesy of FORD MOTOR COMPANY
  42. NOTE: Apply clean engine coolant to the O-ring seal prior to installation.

    Using a new O-ring seal, install the coolant inlet tube and thermostat assembly.

    GFD91681Courtesy of FORD MOTOR COMPANY
  43. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:

    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees
    • Stage 5: Tighten 45 degrees.

    GFD91752Courtesy of FORD MOTOR COMPANY
  44. Install the M6 bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91753Courtesy of FORD MOTOR COMPANY
  45. NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.

    Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:

    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees
    • Stage 5: Tighten 45 degrees.

    GFD91754Courtesy of FORD MOTOR COMPANY
  46. Install the M6 bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91755Courtesy of FORD MOTOR COMPANY
  47. NOTE: The valve tappets must be installed in their original positions.
    NOTE: Coat the valve tappets with clean engine oil prior to installation.
    NOTE: LH shown, RH similar.

    Install the 24 valve tappets.

    GFD91639Courtesy of FORD MOTOR COMPANY
  48. NOTE: Align the bracket with the index mark made during removal.

    Install the upper intake manifold bracket and the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91680Courtesy of FORD MOTOR COMPANY
  49. Install the engine lifting eye and the 2 bolts.

    • Tighten to 24 Nm (18 lb-ft).

    GFD91651Courtesy of FORD MOTOR COMPANY
  50. Install the RH primary timing chain guide and the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91505Courtesy of FORD MOTOR COMPANY
  51. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

    Position the crankshaft dowel pin in the 9 o'clock position.

    GFD91756Courtesy of FORD MOTOR COMPANY
  52. NOTE: Coat the camshafts with clean engine oil prior to installation.

    Position the camshafts onto the RH cylinder head in the neutral position as shown.

    GFD91757Courtesy of FORD MOTOR COMPANY
  53. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

    Position the 4 RH camshaft seals gaps as shown.

    GFD91758Courtesy of FORD MOTOR COMPANY
  54. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the 6 RH camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.

    • Tighten to 8 Nm (71 lb-in) then additional 45 degrees.

    Fig 6: RH Camshaft Cap Bolt Tightening Sequence
    GFD91759Courtesy of FORD MOTOR CO.
  55. Loosen the 4 RH camshaft caps bolts.
    GFD91760Courtesy of FORD MOTOR COMPANY
  56. Tighten the 4 RH camshaft caps bolts in the sequence shown.

    • Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.

    GFD91761Courtesy of FORD MOTOR COMPANY
  57. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to Valve Clearance Check .

    GFD91387Courtesy of FORD MOTOR COMPANY
  58. Remove the 3 bolts and the RH valve train oil tube.
    GFD91478Courtesy of FORD MOTOR COMPANY
  59. Rotate the RH camshafts to the TDC position as shown.
    GFD91762Courtesy of FORD MOTOR COMPANY
  60. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install the Camshaft Holding Tool onto the flats of the RH camshafts.

    GFD91479Courtesy of FORD MOTOR COMPANY
  61. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
    GFD91526Courtesy of FORD MOTOR COMPANY
  62. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.

    • Align the colored links with the timing marks.

    GFD91515Courtesy of FORD MOTOR COMPANY
  63. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

    Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.

    GFD91504Courtesy of FORD MOTOR COMPANY
  64. Install the 2 new RH VCT bolts and tighten in 4 stages.

    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.

    GFD91503Courtesy of FORD MOTOR COMPANY
  65. NOTE: The 2 VCT oil control solenoids are removed for clarity.

    Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down.

    • Make sure the secondary timing chain is centered on the timing chain tensioner guides.

    GFD91502Courtesy of FORD MOTOR COMPANY
  66. NOTE: Coat the camshafts with clean engine oil prior to installation.

    Position the camshafts onto the LH cylinder head in the neutral position as shown.

    GFD91763Courtesy of FORD MOTOR COMPANY
  67. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

    Position the 4 LH camshaft seals gaps as shown.

    GFD91764Courtesy of FORD MOTOR COMPANY
  68. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

    Install the 6 LH camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.

    • Tighten to 8 Nm (71 lb-in) then additional 45 degrees.

    Fig 7: LH Camshaft Cap Bolt Tightening Sequence
    GFD91765Courtesy of FORD MOTOR CO.
  69. Loosen the 4 LH camshaft caps bolts.
    GFD91766Courtesy of FORD MOTOR COMPANY
  70. Tighten the 4 LH camshaft caps bolts in the sequence shown.

    • Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.

    GFD91767Courtesy of FORD MOTOR COMPANY
  71. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to Valve Clearance Check .

    GFD91387Courtesy of FORD MOTOR COMPANY
  72. Remove the 3 bolts and the LH valve train oil tube.
    GFD91476Courtesy of FORD MOTOR COMPANY
  73. Rotate the LH camshafts to the TDC position as shown.
    GFD91768Courtesy of FORD MOTOR COMPANY
  74. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.

    Install the Camshaft Holding Tool onto the flats of the LH camshafts.

    GFD91477Courtesy of FORD MOTOR COMPANY
  75. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
    GFD91527Courtesy of FORD MOTOR COMPANY
  76. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.

    • Align the colored links with the timing marks.

    GFD91522Courtesy of FORD MOTOR COMPANY
  77. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.

    Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.

    GFD91501Courtesy of FORD MOTOR COMPANY
  78. Install the 2 new LH VCT bolts and tighten in 4 stages.

    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.

    GFD91500Courtesy of FORD MOTOR COMPANY
  79. NOTE: The 2 VCT oil control solenoids are removed for clarity.

    Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down.

    • Make sure the secondary timing chain is centered on the timing chain tensioner guides.

    GFD91499Courtesy of FORD MOTOR COMPANY
  80. Install the LH upper primary timing chain guide and the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91666Courtesy of FORD MOTOR COMPANY
  81. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
    GFD91769Courtesy of FORD MOTOR COMPANY
  82. Install the crankshaft timing chain sprocket.
    GFD91486Courtesy of FORD MOTOR COMPANY
  83. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.

    Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.

    GFD91489Courtesy of FORD MOTOR COMPANY
  84. Install the lower LH primary timing chain guide and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD91485Courtesy of FORD MOTOR COMPANY
  85. Install the primary timing chain tensioner arm.
    GFD91484Courtesy of FORD MOTOR COMPANY

    Late build vehicles 

  86. Reset the primary timing chain tensioner.

    1. Position the tensioner in a soft-jawed vise.
    2. Using pliers, squeeze the ends of the ratchet wire clip together.
    3. Using the soft-jawed vise, compress the plunger to the reset position.
    4. Install a locking pin in the 2 holes of the tensioner body to hold the plunger in place.

    GFD231082Courtesy of FORD MOTOR COMPANY
  87. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.

    Install the primary tensioner and the 2 bolts.

    1. Tighten to 10 Nm (89 lb-in).
    2. Remove the lockpin.

    GFD231083Courtesy of FORD MOTOR COMPANY

    Early build vehicles 

  88. Reset the primary timing chain tensioner.

    • Release the ratchet detent.
    • Using a soft-jawed vise, compress the ratchet plunger.
    • Align the hole in the ratchet plunger with the hole in the tensioner housing.
    • Install a suitable lockpin.

    GFD91490Courtesy of FORD MOTOR COMPANY
  89. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.

    Install the primary tensioner and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.

    GFD91491Courtesy of FORD MOTOR COMPANY

    All vehicles 

  90. As a post-check, verify correct alignment of all timing marks.

    • There are 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
    • There are 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).

    GFD91492Courtesy of FORD MOTOR COMPANY
  91. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
    NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    Install the LH intake VCT oil control solenoid and the bolt.

    • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.

    GFD91495Courtesy of FORD MOTOR COMPANY
  92. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.
    NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    Install the RH intake VCT oil control solenoid and the bolt.

    • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.

    GFD91496Courtesy of FORD MOTOR COMPANY
  93. Remove the RH Camshaft Holding Tool.
    GFD91479Courtesy of FORD MOTOR COMPANY
  94. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages.

    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

    GFD91478Courtesy of FORD MOTOR COMPANY
  95. Remove the LH Camshaft Holding Tool.
    GFD91477Courtesy of FORD MOTOR COMPANY
  96. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages.

    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 45 degrees.

    GFD91476Courtesy of FORD MOTOR COMPANY
  97. NOTE: Only use a 3M™ Roloc ® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.

    Clean the engine front cover using a 3M™ Roloc ® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 RPM.

    • Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

  98. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc ® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces of engine block, cylinder heads, and oil pan. These tools can cause contamination that will cause premature engine failure. Remove all traces of the gasket.

    Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.

    1. Remove any large deposits of silicone or gasket material.
    2. Apply silicone gasket remover and allow to set for several minutes.
    3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
    5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

  99. Install the Alignment Pins.
    GFD91424Courtesy of FORD MOTOR COMPANY
  100. NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

    Apply a 3.0 mm (0.11 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 4 inner bolt bosses.

    • Apply a 5.5 mm (0.21 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.

    GFD91425Courtesy of FORD MOTOR COMPANY
  101. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

    Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22.

    • Tighten in sequence to 3 Nm (27 lb-in).

    GFD91426Courtesy of FORD MOTOR COMPANY
  102. Remove the Alignment Pins.
    GFD91427Courtesy of FORD MOTOR COMPANY
  103. NOTE: Do not tighten the bolt at this time.

    Install the M6 engine front cover bolt.

    GFD91422Courtesy of FORD MOTOR COMPANY
  104. NOTE: Do not tighten the bolts at this time.

    Install the 3 M10 engine front cover bolts.

    GFD91770Courtesy of FORD MOTOR COMPANY
  105. NOTE: Do not expose the Motorcraft ® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

    Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 7 stages:

    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in).
    • Stage 2: Tighten bolts 23, 24 and 25 to 15 Nm (133 lb-in).
    • Stage 3: Tighten bolt 26 to 10 Nm (89 lb-in).
    • Stage 4: Loosen bolt 26 one full turn.
    • Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lb-ft) plus an additional 90 degrees.
    • Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional 45 degrees.
    • Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional 45 degrees.

    GFD91428Courtesy of FORD MOTOR COMPANY
  106. NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure (EOP) switch threads.

    Install the EOP switch.

    • Tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.

    GFD91678Courtesy of FORD MOTOR COMPANY
  107. Install and connect the Cylinder Head Temperature (CHT) sensor jumper harness.
    GFD91654Courtesy of FORD MOTOR COMPANY
  108. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    GFD231094Courtesy of FORD MOTOR COMPANY
  109. Install the fuel supply tube-to-engine front cover bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91635Courtesy of FORD MOTOR COMPANY
  110. Install the 2 thermostat housing-to-lower intake manifold bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD91653Courtesy of FORD MOTOR COMPANY
  111. NOTE: Lubricate the 2 Camshaft Position (CMP) sensor O-ring seals with clean engine oil.

    Install the 2 RH CMP sensors and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD91648Courtesy of FORD MOTOR COMPANY
  112. NOTE: Lubricate the 2 CMP sensor O-ring seals with clean engine oil.

    Install the 2 LH CMP sensors and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD91658Courtesy of FORD MOTOR COMPANY
  113. Install the cover and the pin-type retainer.
    GFD91676Courtesy of FORD MOTOR COMPANY
  114. Install the LH cylinder block drain plug.

    • Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.

    GFD91649Courtesy of FORD MOTOR COMPANY
  115. Install the RH cylinder block drain plug or, if equipped, the block heater.

    • Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
    • Tighten the block heater to 40 Nm (30 lb-ft).

    GFD91650Courtesy of FORD MOTOR COMPANY

    Front Wheel Drive (FWD) vehicles 

  116. Install 6 new RH exhaust manifold studs.

    • Tighten to 12 Nm (106 lb-in).

    GFD91772Courtesy of FORD MOTOR COMPANY
  117. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:

    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).

    GFD91773Courtesy of FORD MOTOR COMPANY
  118. Install the RH catalytic converter heat shield, Catalyst Monitor Sensor (CMS) wiring harness bracket and the 4 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD91620Courtesy of FORD MOTOR COMPANY

    All vehicles 

  119. Install 6 new LH exhaust manifold studs.

    • Tighten to 12 Nm (106 lb-in).

    GFD91774Courtesy of FORD MOTOR COMPANY
  120. Using a new gasket, install the LH catalytic converter and 3 new lower LH catalytic converter manifold-to-cylinder head nuts.

    • Install the 3 new upper LH catalytic converter manifold-to-cylinder head nuts and tighten to 25 Nm (18 lb-ft).
    • Tighten the 3 lower LH catalytic converter manifold-to-cylinder head nuts to 25 Nm (18 lb-ft).

    GFD91775Courtesy of FORD MOTOR COMPANY
  121. Install the LH exhaust heat shield and the 3 bolts.

    • Tighten to 10 Nm (89 lb-in).

    GFD91663Courtesy of FORD MOTOR COMPANY
  122. Position the wiring harness onto the engine and connect the EOP switch electrical connector and the wiring harness pin-type retainer.
    GFD91662Courtesy of FORD MOTOR COMPANY
  123. Install the generator stud, generator and the nut and bolt.

    • Tighten the stud to 8 Nm (7 lb-in).
    • Tighten the nut and bolt to 47 Nm (35 lb-ft).

    GFD91661Courtesy of FORD MOTOR COMPANY
  124. Connect the generator B+ cable and install the nut.

    • Tighten to 17 Nm (150 lb-in).

    GFD91614Courtesy of FORD MOTOR COMPANY
  125. Position back the generator B+ cable cover and connect the generator electrical connector.
    GFD91613Courtesy of FORD MOTOR COMPANY
  126. Connect the 2 A/C compressor electrical connectors.

    • Attach the A/C wiring harness retainer.

    GFD91612Courtesy of FORD MOTOR COMPANY
  127. NOTE: Oil filter adapter with oil cooler shown, oil filter adapter without oil cooler similar.

    Using a new gasket, install the oil filter adapter and the 3 bolts.

    • Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.

    GFD91446Courtesy of FORD MOTOR COMPANY
  128. If equipped, using a new gasket, install the oil cooler and the 6 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    GFD91776Courtesy of FORD MOTOR COMPANY
  129. Install the Crankshaft Position (CKP) sensor and install the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91674Courtesy of FORD MOTOR COMPANY
  130. Connect the CKP sensor electrical connector.
    GFD91673Courtesy of FORD MOTOR COMPANY
  131. Install the wiring harness grommet.
    GFD91672Courtesy of FORD MOTOR COMPANY
  132. Install the wiring harness retainer stud bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91671Courtesy of FORD MOTOR COMPANY
  133. Install the heat shield, the nut and the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91670Courtesy of FORD MOTOR COMPANY
  134. Install the ground cable and the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91611Courtesy of FORD MOTOR COMPANY
  135. Connect the 2 RH Camshaft Position Camshaft Position (CMP) sensor electrical connectors.
    GFD91647Courtesy of FORD MOTOR COMPANY
  136. Connect the KS electrical connector.
    GFD91669Courtesy of FORD MOTOR COMPANY
  137. NOTE: Installation of new seals is only required if damaged seals were removed.

    Using the VCT Spark Plug Tube Seal Installer and Handle, install new RH spark plug tube seals.

    GFD91558Courtesy of FORD MOTOR COMPANY
  138. NOTE: Installation of new seals is only required if damaged seals were removed.

    Using the Differential Bearing Cone Installer and Handle, install new RH VCT solenoid seal(s).

    GFD91559Courtesy of FORD MOTOR COMPANY
  139. NOTE: Failure to use the correct Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

    Apply an 8 mm (0.31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.

    GFD91560Courtesy of FORD MOTOR COMPANY
  140. Using a new gasket, install the RH valve cover and tighten the 2 bolts and 9 stud bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    GFD91561Courtesy of FORD MOTOR COMPANY
  141. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
    GFD91551Courtesy of FORD MOTOR COMPANY
  142. NOTE: Installation of new seals is only required if damaged seals were removed.

    Using the VCT Spark Plug Tube Seal Installer and Handle, install new LH spark plug tube seals.

    GFD91547Courtesy of FORD MOTOR COMPANY
  143. NOTE: Installation of new seals is only required if damaged seals were removed.

    Using the Differential Bearing Cone Installer and Handle, install new LH VCT solenoid seal(s).

    GFD91548Courtesy of FORD MOTOR COMPANY
  144. NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

    Apply an 8 mm (0.31 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

    GFD91549Courtesy of FORD MOTOR COMPANY
  145. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).

    GFD91550Courtesy of FORD MOTOR COMPANY
  146. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
    GFD91551Courtesy of FORD MOTOR COMPANY
  147. NOTE: On All-Wheel Drive (AWD) vehicles the Catalyst Monitor Sensor (CMS) electrical connector will be connected during the engine installation procedure.

    Install the engine wiring harness to the RH valve cover.

    • Position the wiring harness and attach the 9 wiring harness retainers to the RH valve cover and stud bolts.
    • Connect the CHT sensor wiring harness jumper electrical connector.
    • Connect the 3 fuel injector electrical connectors.
    • Connect and attach the RH CMS electrical connector.
    • Connect the 2 VCT oil control solenoid electrical connectors.

    GFD91554Courtesy of FORD MOTOR COMPANY
  148. Install the PCV crankcase vent tube.
    GFD91553Courtesy of FORD MOTOR COMPANY
  149. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs.

    Install the 3 RH coil-on-plugs and the 3 bolts.

    • Tighten to 7 Nm (62 lb-in).
    • Connect the 3 coil-on-plug electrical connectors.

    GFD91552Courtesy of FORD MOTOR COMPANY
  150. Using a new gasket, install the intake manifold and the 7 bolts.

    • Tighten in the sequence shown in 2 stages.

      • Stage 1: Tighten to 10 Nm (89 lb-in).
      • Stage 2: Tighten an additional 45 degrees.

    GFD231086Courtesy of FORD MOTOR COMPANY
  151. Install the upper intake manifold support bracket bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91532Courtesy of FORD MOTOR COMPANY
  152. Attach the 2 coolant tube retainers to the upper intake manifold.
    GFD91531Courtesy of FORD MOTOR COMPANY
  153. Connect the crankcase ventilation hose to the upper intake manifold.
    GFD91634Courtesy of FORD MOTOR COMPANY
  154. Connect the EVAP vapor tube to the EVAP canister vent solenoid. For additional information, refer to Fuel System General Information .

    • Attach the EVAP vapor tube to the 2 retainers.

    GFD91529Courtesy of FORD MOTOR COMPANY
  155. Connect the MAPT electrical connector.

    • Attach the wiring harness pin-type retainer to the upper intake manifold.

    GFD231090Courtesy of FORD MOTOR COMPANY
  156. Connect the EVAP canister vent solenoid and throttle body electrical connectors.

    • Attach the wiring harness pin-type retainer to the upper intake manifold.

    GFD91528Courtesy of FORD MOTOR COMPANY
  157. Install the wiring harness retainer to the rear of the LH cylinder head.
    GFD91659Courtesy of FORD MOTOR COMPANY
  158. Connect the 2 LH Camshaft Position (CMP) sensor electrical connectors.
    GFD91657Courtesy of FORD MOTOR COMPANY
  159. Install the engine wiring harness to the LH valve cover.

    • Position the wiring harness and attach the 11 wiring harness retainers to the LH valve cover and stud bolts.
    • Connect the 3 fuel injector electrical connectors.
    • Connect and attach the LH HO2S electrical connector.
    • Connect the 2 VCT oil control solenoid electrical connectors.

    GFD91543Courtesy of FORD MOTOR COMPANY
  160. Position the wire harness ground to the engine front cover and install the bolt.

    • Tighten to 10 Nm (89 lb-in).

    GFD91633Courtesy of FORD MOTOR COMPANY
  161. Install the oil level indicator.
    GFD91541Courtesy of FORD MOTOR COMPANY
  162. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs.

    Install the 3 LH -coil-on-plugs and the 3 bolts.

    • Tighten to 7 Nm (62 lb-in.
    • Connect the 3 coil-on-plug electrical connectors.

    GFD91540Courtesy of FORD MOTOR COMPANY
  163. Install the crankcase vent tube. For additional information, refer to the quick connect coupling procedure in Fuel System General Information .
    GFD91539Courtesy of FORD MOTOR COMPANY
  164. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

    Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.

    GFD91392Courtesy of FORD MOTOR COMPANY
  165. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

    Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.

    GFD91398Courtesy of FORD MOTOR COMPANY
  166. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.

    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.

    GFD91777Courtesy of FORD MOTOR COMPANY
  167. Install the accessory drive belt tensioner and the 3 bolts.

    • Tighten to 11 Nm (97 lb-in).

    GFD91631Courtesy of FORD MOTOR COMPANY
  168. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.

    • Connect the block heater electrical connector.

    GFD91646Courtesy of FORD MOTOR COMPANY
  169. If equipped, install the block heater heat shield.
    GFD91645Courtesy of FORD MOTOR COMPANY
  170. Install the Engine Lift Eye on the LH cylinder head.
    GFD91605Courtesy of FORD MOTOR COMPANY
  171. Using the Floor Crane and Spreader Bar, remove the engine from the stand.
    GFD91606Courtesy of FORD MOTOR COMPANY
  172. Install the crankshaft sensor ring.
    GFD91400Courtesy of FORD MOTOR COMPANY
  173. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.

    Install the flexplate and the 8 bolts.

    • Tighten in the sequence shown to 80 Nm (59 lb-ft).

GFD91435Courtesy of FORD MOTOR COMPANY
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